SUBARU LEGACY 1997 Service Repair Manual

5. Crankshaft and Piston
B2M0683A

1Drive plate


2Reinforcement


3Top ring


4Second ring


5Oil ring


6Piston


7Piston pin


8Circlip


9Connecting rod bolt


10Connecting rod


11Connecting rod bearing

12Connecting rod cap


13Crankshaft


14Woodruff key


15Crankshaft bearing #1, #5


16Crankshaft bearing #2, #4


17Crankshaft bearing #3
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 44±2 (4.5±0.2, 32.5±1.4)
T2: 72±3 (7.3±0.3, 52.8±2.2)
10
2-3bCOMPONENT PARTS
5. Crankshaft and Piston

G2M0709
1. General Precautions
1) Before disassembling engine, place it on ST3.
ST1 498457000 ENGINE STAND ADAPTER RH
ST2 498457100 ENGINE STAND ADAPTER LH
ST3 499817000 ENGINE STAND
2) All parts should be thoroughly cleaned, paying special
attention to the engine oil passages, pistons and bearings.
3) Rotating parts and sliding parts such as piston, bearing
and gear should be coated with oil prior to assembly.
4) Be careful not to let oil, grease or coolant contact the
timing belt, clutch disc and flywheel.
5) All removed parts, if to be reused, should be reinstalled
in the original positions and directions.
6) Gaskets and lock washers must be replaced with new
ones. Liquid gasket should be used where specified to
prevent leakage.
7) Bolts, nuts and washers should be replaced with new
ones as required.
8) Even if necessary inspections have been made in
advance, proceed with assembly work while making
rechecks.
11
2-3bSERVICE PROCEDURE
1. General Precautions

2. Timing Belt
A: REMOVAL
1. CRANKSHAFT PULLEY AND BELT COVER
B2M1215A
G2M0711
1) Remove V-belt cover, V-belt and air conditioning com-
pressor drive belt tensioner.
2) Remove pulley bolt. To lock crankshaft, use ST.
ST 499977100 CRANKSHAFT PULLEY WRENCH
3) Remove crankshaft pulley.
B2M0729
4) Remove left-hand belt cover.
12
2-3bSERVICE PROCEDURE
2. Timing Belt

B2M0730
5) Remove right-hand belt cover.
B2M0731
6) Remove front belt cover.
13
2-3bSERVICE PROCEDURE
2. Timing Belt

2. TIMING BELT
B2M0685A
G2M0713
B2M0686A
1) If alignment mark and/or arrow mark (which indicates
rotation direction) on timing belt fade away, put new marks
before removing timing belt as follows:
(1) Turn crankshaft using ST, and align alignment
marks on crankshaft sprocket, left-hand intake cam-
shaft sprocket, left-hand exhaust camshaft sprocket,
right-hand intake camshaft sprocket and right hand
exhaust camshaft sprocket with notches of belt cover
and cylinder block.
ST 499987500 CRANKSHAFT SOCKET
14
2-3bSERVICE PROCEDURE
2. Timing Belt

B2M0687A
(2) Using white paint, put alignment and/or arrow
marks on timing belts in relation to the sprockets.
Z
1: 54.5 tooth length
Z
2: 51 tooth length
Z
3: 28 tooth length
B2M0688
B2M0689
G2M0739
2) Loosen tensioner adjuster mounting bolts.
3) Remove belt idler.
B2M0733
4) Remove timing belt.
5) Remove belt idler No. 2.
CAUTION:
After timing belt has been removed, never rotate intake
and exhaust, camshaft sprocket.
If camshaft sprocket is rotated, the intake and exhaust
valve heads strike together and valve stems are bent.
15
2-3bSERVICE PROCEDURE
2. Timing Belt

3. BELT TENSIONER AND IDLER
B2M0690A
B2M0732
1) Remove belt idler.
B2M0733
2) Remove belt idler No. 2.
B2M0734
3) Remove belt tensioner and spacer.
16
2-3bSERVICE PROCEDURE
2. Timing Belt

B2M0735
4) Remove belt tension adjuster.
4. SPROCKET
B2M0691A
H2M1294A
1) Remove left-hand intake camshaft sprocket.
2) Remove left-hand exhaust camshaft sprocket.
3) Remove right-hand intake camshaft sprocket.
4) Remove right-hand exhaust camshaft sprocket.
ST 499207300 CAMSHAFT SPROCKET WRENCH
5) Remove crankshaft sprocket.
B2M0736
6) Remove tensioner bracket.
17
2-3bSERVICE PROCEDURE
2. Timing Belt

B2M0737
7) Remove left-hand belt cover No. 2.
B2M0738
8) Remove right-hand belt cover No. 2.
B: INSPECTION
1. TIMING BELT
1) Check timing belt teeth for breaks, cracks, and wear. If
any fault is found, replace belt.
2) Check the condition of back side of belt; if any crack is
found, replace belt.
CAUTION:
Be careful not to let oil, grease or coolant contact
the belt. Remove quickly and thoroughly if this hap-
pens.
G2M0115
Do not bend the belt sharply.
Bending radius: h
60 mm (2.36 in) or more
18
2-3bSERVICE PROCEDURE
2. Timing Belt

2. BELT TENSION ADJUSTER
1) Visually check oil seals for leaks, and rod ends for
abnormal wear or scratches. If necessary, replace belt ten-
sion adjuster.
CAUTION:
Slight traces of oil at rod’s oil seal does not indicate a
problem.
2) While holding tensioner with both hands, push the rod
section against floor or wall ensuring the rod section will
react as follows:
(1) When applying a force of 147 N (15 kg, 33 lb), the
rod section should not sink.
(2) When applying a force of 147 to 490 N (15 to 50 kg,
33 to 110 lb), the rod section should maintain a projec-
tionally acting force and should not sink within 8.5 sec-
onds.
B2M0108A
3) Measure the extension of rod beyond the body. If it is
not within specifications, replace with a new one.
Rod extension: H
15.4 — 16.4 mm (0.606 — 0.646 in)
3. BELT TENSIONER
1) Check mating surfaces of timing belt and contact point
of tension adjuster rod for abnormal wear or scratches.
Replace belt tensioner if faulty.
2) Check spacer and tensioner bushing for wear.
3) Check tensioner for smooth rotation. Replace if noise or
excessive play is noted.
4) Check tensioner for grease leakage.
4. BELT IDLER
1) Check idler for smooth rotation. Replace if noise or
excessive play is noted.
2) Check outer contacting surfaces of idler pulley for
abnormal wear and scratches.
3) Check idler for grease leakage.
19
2-3bSERVICE PROCEDURE
2. Timing Belt